Systems and processes for reinforcing components of articles of wear

ABSTRACT

Systems and processes for reinforcing components of articles of wear are disclosed. The processes can include applying a thermoplastic powder to a component of an article of wear and levelling at least a portion of the thermoplastic powder. The processes can also include applying thermal energy to the component and the thermoplastic powder. Further, the processes can include compressing the thermoplastic powder and the component.

CROSS-REFERENCE INFORMATION

This Application having Ser. No. 15/901,646 and entitled “Systems andProcesses for Reinforcing Components of Articles of Wear” claimspriority of Vietnam Application Number VN 1-2017-00602, filed Feb. 21,2017, and entitled “Systems and Processes for Reinforcing Components ofArticles of Wear”. The entirety of the aforementioned application isincorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates to components of articles of wear. Moreparticularly, the present disclosure relates to methods and systems forreinforcing components of articles of wear.

BACKGROUND

Traditional methods of manufacturing certain articles of wear, e.g.,articles of footwear, include the cutting and combining of individualcomponents. However, the cutting and combining of multiple componentscan be labor-intensive, and can be error-prone processes resulting inmanufacturing defects. Further, such errors can lead to increased wasteand reduced manufacturing efficiencies.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative aspects of the present invention are described in detailbelow with reference to the attached drawing figures, which areincorporated by reference herein and wherein:

FIG. 1A is a top and side perspective view of an exemplary system forreinforcing a footwear component that includes a powder applicator, aleveler, a thermal energy source, an un-bonded powder removal station,and a press, in accordance with aspects hereof;

FIG. 1B is a cross-sectional view of a footwear component along thecutline 1B prior to receiving thermoplastic powder from the powderapplicator of the system in FIG. 1A;

FIG. 1C is a cross-sectional view of a footwear component along thecutline 1C after receiving thermoplastic powder from the powderapplicator of the system in FIG. 1A;

FIG. 1D is a cross-sectional view of a footwear component along thecutline 1D after being exposed to the leveler and while being exposed tothe thermal energy source both from the system of FIG. 1A;

FIG. 1E is a cross-sectional view of a footwear component along thecutline 1E after being exposed to the un-bonded powder removal stationfrom the system of FIG. 1A;

FIG. 1F is a cross-sectional view of a footwear component along thecutline 1F after being exposed to the roller from the system of FIG. 1A;

FIG. 2 is top and side perspective view of another exemplary system forreinforcing a footwear component that includes a vision system, a powderapplicator, a thermal energy source, an un-bonded powder removalstation, a heating chamber, and a press, in accordance with aspectshereof;

FIG. 3 is a top and side perspective view of an exemplary article offootwear, in accordance with aspects hereof; and

FIG. 4 is a flow diagram of a method for reinforcing a footwearcomponent, in accordance with aspects hereof.

DESCRIPTION

In general, aspects herein are directed systems and methods forreinforcing a component for an article of wear, such as an article offootwear. Traditionally, when manufacturing an article of wear, e.g., anarticle of footwear, multiple layers and/or components may be cut andcombined together to provide various functional characteristics to thearticle of footwear, such as resistance to tear, or a restriction ofelasticity. However, the cutting and combining of multiple layers and/orcomponents invites manufacturing error at each step, which can result inproduct defects. In addition, the cutting of individual layers and/orcomponents can result in significant waste.

The processes and systems disclosed herein can alleviate one or moreproblems discussed above. In aspects, at a high level, the processesdisclosed herein utilized deposition manufacturing techniques to bond areinforcing component to an article of wear with less error, greaterefficiency, and reduced waste compared to traditional manufacturingprocesses.

In certain aspects, the processes described herein can apply areinforcing component material, e.g., a thermoplastic powder, to anupper for an article of footwear. In aspects, the thermoplastic powdercan be indiscriminately applied, e.g., applied over substantially anentire surface of the upper. Further, in such aspects, the reinforcingcomponent material can be selectively bonded to the upper by applyingthermal energy, e.g., originating from a laser energy source, to adesired area of the upper and/or a desired area of the thermoplasticpowder on the upper. In such aspects, this process can result inincreased efficiency, since the application of thermal energy alone maydefine the size and shape of the reinforced area, as opposed tospecifically placing the thermoplastic powder into the size and shape ofthe reinforced area and then securing it thereto.

In aspects, the indiscriminate application of the thermoplastic powderfollowed by the selective application of thermal energy results inreduced manufacturing error since the number of precision steps isreduced compared to conventional manufacturing processes. For example,in conventional manufacturing processes the reinforcing component may beprecisely cut and then precisely placed and attached to the upper in aspecific location, whereas the processes described herein can includethe imprecise or indiscriminate application of the thermoplastic powderto the upper followed by the selective application of thermal energy toform, shape, and at least partially bond the reinforcing component tothe upper.

In aspects, as further discussed below, the orientation, position, size,and/or shape of the upper can be visually or thermally determined priorto applying thermal energy to the upper. This can result in reducederror and handling of the upper since the upper can be presented to thesystem in an orientation-independent manner. Further, such a feature canprovide increased manufacturing efficiency since the system can detectdifferent sizes or shapes of uppers and modify the application ofthermal energy accordingly, without having to change manufacturingequipment specific to a type of size and/or shape of an upper.

In aspects, the selective application of thermal energy to thethermoplastic powder and/or the upper can result in the thermoplasticpowder being partially sintered together and/or partially bonded to theupper while the remaining portions of the thermoplastic powder nottargeted by the thermal energy remain un-bonded (and/or not sintered).The un-bonded thermoplastic powder on the upper can then be recoveredand recycled for potential re-use, resulting in reduced waste.

In aspects, once the thermoplastic powder is sintered together and/orpartially bonded to the upper and the un-bonded powder is removed, thereinforcement component can be compressed and fused to get the desireddensity and adhesion level of reinforced component on the upper. Incertain aspects, the processes described herein may also result in lessuse or no use of hot adhesives traditionally used to reinforce portionsof an upper, since the thermoplastic powder can be bonded or fixed tothe footwear component itself without application of an adhesive.

Accordingly, in one aspect a method of reinforcing a footwear componentis provided. The method includes applying a thermoplastic powder to thefootwear component and leveling at least a portion of the thermoplasticpowder. The method also includes selectively applying thermal energy tothe footwear component to at least partially bond the thermoplasticpowder with the footwear component. Further the method includescompressing the thermoplastic powder and the footwear component.

In another aspect, a system of reinforcing a footwear component isprovided. The system includes a powder applicator that applies athermoplastic powder to the footwear component; and a leveler thatlevels at least a portion of the thermoplastic powder. The leveler canbe positioned a defined height above the footwear component. The systemalso includes a thermal energy source that applies thermal energy to thefootwear component to at least partially bond the thermoplastic powderwith the footwear component. Further, the system includes a press thatcompresses the thermoplastic powder and the footwear component.

Turing now to the Figures, and FIG. 1A in particular, a system 100 forreinforcing a footwear component is depicted. It should be understoodthat while a footwear component is utilized in the description of thesystem 100, such a system is also applicable to other articles of wear,such as for the reinforcement of shirts, pants, socks, or sportprotective equipment. In one or more aspects, as discussed furtherbelow, the reinforcement of the footwear component, or another componentof an article of wear, can: function as a rip stop; function asstructural reinforcement, limit the stretch of a footwear componentmaterial; or function as a dimensional offset for airflow.

As can be seen in FIG. 1A, the system 100 can include a powderapplicator 104, a leveler 106, a thermal energy source 108, an un-bondedpowder removal station 110, and a press 112. In various aspects, aconveyance system 102 can transfer a footwear component 101 to thevarious components of the system 100. The conveyance system 102 caninclude any conventional conveyance system, such as a linear beltconveyance system. It should be understood that the footwear component101 is schematically depicted and does not represent the size and/orshape of a particular footwear component. In certain aspects, thefootwear component 101 is positioned lying substantially flat on thesurface of the conveyance system 102.

In certain aspects, the footwear component 101 can be transferred to thepowder applicator 104 via the conveyance system 102. In certain aspects,one or more components of the system 100 can include a sensor so thatsuch a component is triggered to act on the footwear component 101transferred to it, while the conveyance system 102 may continuously run.

In aspects, once the footwear component 101 is transferred to a positionunderneath the powder applicator 104, the powder applicator 104 canapply a thermoplastic powder 105 to the footwear component 101. FIGS. 1Band 1C depict cross-sectional views of the footwear component along therespective cutlines 1B and 1C before application of the thermoplasticpowder (FIG. 1B) and after application of the thermoplastic powder FIG.1C.

The powder applicator 104 can be any commercially available powderapplicator that is capable of applying a thermoplastic powder to thefootwear component 101. In certain aspects, the thermoplastic powder 105can be any commercially available thermoplastic material in powder formthat can be used for reinforcing footwear components. A non-limitinglist of thermoplastic powders includes a polyurethane material, apolyester material, a polyamide material, a polyolefin material, anethylene vinyl acetate material, or a combination thereof.

In one or more aspects, once the thermoplastic powder 105 has beenapplied to the footwear component 101, the conveyance system 102 cantransfer the footwear component 101 to a leveler 106. In aspects, theleveler 106 can level the thermoplastic powder 105 that has been appliedto the article of footwear 101. In such aspects, the leveler 106 canensure that a substantially even amount or thickness of thethermoplastic powder 105 is present on the footwear component 101. FIG.1D is a cross-sectional view of the footwear component 101 along thecutline 1D after being exposed to the leveler 106, showing thesubstantially even amount of thermoplastic powder on the footwearcomponent.

In one or more aspects, the leveler 106 can include a substantially flatbar for scraping off thermoplastic powder 105 on the footwear component101 as the footwear component 101 is conveyed along the conveyancesystem 102. In certain aspects, the leveler 106 can be verticallyadjustable to control the thickness of the thermoplastic powder 105 onthe footwear component 101. It should be understood that other powderleveling mechanisms can be utilized in this system 100, and that theleveler 106 is just one example depicted for leveling the appliedthermoplastic powder 105.

In various aspects, the footwear component 101 with the levelledthermoplastic powder 105 can be transferred to a thermal energy source,such as the thermal energy source 108. In aspects, the thermal energysource 108 can include any thermal energy source that is capable of atleast partially bonding the thermoplastic powder 105 with the footwearcomponent 101. In one aspect, the thermal energy source 108 can includea laser energy source. In certain aspects, the laser energy source caninclude a 300 Watt CO₂ laser with a computer controlled Galvanometerpositioning head.

In one or more aspects, the thermal energy source 108 can cause at leasta portion of the thermoplastic powder 105 to melt or deform such thatthe melted or deformed thermoplastic powder 105 at least partially bondsto the footwear component 101 and/or to adjacent thermoplastic powderparticles. In certain aspects, the thermoplastic powder 105 may havemelted or deformed such that it can at least partially penetrate into orform about the footwear component material so as to become at leastpartially physically bonded thereto.

In one or more aspects, the thermal energy source 108, e.g., a laserenergy source, is capable of directing laser energy to all or a portionof the footwear component 101 to at least partially bond thethermoplastic powder 105 thereto. For example, in one aspect, the laserenergy source can move in a path so as to cover all or a portion of thefacing surface of the footwear component 101. In certain aspects, thethermal energy source 108 can selectively apply thermal energy in thelocation and shape desired for the forming and bonding of a specificreinforcing component. It should be understood that one skilled in theart can adjust the type and strength of the thermal energy source 108 toapply to the thermoplastic powder 105 and the footwear component 101based on the type and thickness of the thermoplastic powder 105 presentthereon.

In certain aspects, the footwear component 101 after having been exposedto the thermal energy source 108 can be transferred to the un-bondedpowder removal station 110. In such aspects, the un-bonded powderremoval station 110 can include an air nozzle to supply a stream of airsufficient to remove the un-bonded thermoplastic powder withoutsubstantially altering the thermoplastic powder partly bonded to thefootwear component 101. FIG. 1E depicts a cross-section along thecutline 1E of the footwear component 101 showing the at least partiallybonded thermoplastic powder 105 present on the footwear component 101while the un-bonded portion has been removed (compare to FIG. 1D).

In certain aspects, the stream of air can be heated so that the at leastpartially bonded thermoplastic powder 105 can be conditioned for furtherbonding and compression provided by the press 112. In certain aspects,the stream of air can provide an elevated temperature of at least about21 degrees Celsius (° C.), at least about 23° C., or at least about 25°C. to the thermoplastic powder 105. In one aspect, the elevatedtemperature can be above the glass transition temperature of thethermoplastic powder 105 and/or below the melting temperature of thethermoplastic powder 105.

In various aspects, the footwear component 101 can be transferred to thepress 112. In certain aspects, the press 112 can provide a substantiallyeven force to the footwear component 101 so that the partially-bondedthermoplastic powder 105 becomes more permanently attached of fixed tothe footwear component 101. As can be seen in FIG. 1A, in certainaspects, the press 112 can shift vertically, e.g., in order to apply aforce or release from engagement with the footwear component 101. Inaspects, the press 112 can include a planar press that applies acompressive force to the footwear component 101 and the thermoplasticpowder 105 in order to more permanently bond the thermoplastic powder105 to the footwear component 101. In an alternative aspect, thefootwear component 101 and the thermoplastic powder 105 can be exposedto a compressive force via a roller press. FIG. 1F depicts across-sectional view of the footwear component 101 along the cutline 1F.As can be seen in FIG. 1F, the thermoplastic powder 105 has beencompressed (compare to FIG. 1E), which more permanently fixes thethermoplastic powder 105 to the footwear component 101 and also compactsthe thermoplastic powder 105 (increases the density) to provide anincreased reinforcement functionality compared to the un-compactedthermoplastic powder 105.

In certain aspects, once the thermoplastic powder 105 has been morepermanently bonded or fixed to the footwear component 101, thereinforced footwear component can be transferred or conveyed for furtherprocessing, as discussed further below.

FIG. 2 depicts an alternative system 200 for reinforcing an article ofwear, such as an article of footwear. In such aspects, the system 200can be utilized to reinforce a footwear component 201, such as an upperfor the article of footwear. In the aspect depicted in FIG. 2, thesystem 200 can include a vision system 202, a powder applicator 204, athermal energy source 206, an un-bonded powder removal station 208, aheating chamber 210, and a press 212.

In certain aspects, the vision system 202 can be adapted to identify oneor more of the type of footwear component 201, the size of the footwearcomponent 201, and the orientation of the footwear component 201. Incertain aspects, the vision system 202 can be any type of vision systemor scanner capable of identifying the type, size, and orientation of thefootwear component 201. In aspects, the vision system 202 can sensearticles in two or three dimensions. A non-limiting list of specificvision system components includes a closed circuit television camera(CCTV) system, a visible light based sensing system, and an infraredbased sensing system.

In one or more aspects, the vision system 202 can include a computer forreceiving the imaging information, e.g., footwear orientation, size, andtype, and for providing or determining a pattern for where thethermoplastic powder should be at least partially bonded to the footwearcomponent 201. In such aspects, this pattern and/or orientationinformation can be communicated to one or more of the components of thesystem 200, such as the thermal energy source 206. In certain aspects, auser can specify a particular pattern or the computer can apply apredetermined pattern based on the identification of the size and typeof footwear component identified.

In aspects, by utilizing a vision system 202 in communication with othercomponents of the system 200, e.g., the thermal energy source 206, thesystem and processes disclosed herein can provide for a more streamlinedprocess in that reduced labor and less equipment is needed since thesystem 200 would not require the footwear component 201 to be in anyparticular orientation. Further, labor and other equipment can beminimized since the vision system 202 can identify and communicateorientation and pattern information to the thermal energy source 206,thereby obviating or minimizing the need for system modifications, e.g.,modifications for different types of footwear components (or differentsizes of footwear components).

In certain aspects, the system 200 can include a conveyance system 203configured to convey the footwear component 201 between the variouscomponents of the system 200. In aspects, the conveyance system 203 caninclude any conveyance system capable of transferring the footwearcomponent 201 from one system component to the another system component.For example, as can be seen in FIG. 2, the conveyance system 203 caninclude a surface that shifts or rotates the footwear component 201 fromthe vision system 202 to the powder applicator 204, on to the thermalenergy source 206, then to the un-bonded powder removal station 208, tothe heating chamber 210, and then on to the press 212. In certainaspects, the conveyance system 203 and the position of the other systemcomponents 202, 204, 206, 208, 210, and 212 can allow for continuousoperation so that a single movement of the conveyance system 203 toshift a footwear component from one system component to another, alsoshifts other footwear components between the other system components.

In certain aspects, after having been analyzed by the vision system 202,the footwear component 201 can be transferred to the powder applicator204. In certain aspects, like the powder applicator 104 of FIG. 1A, thepowder applicator 204 can apply a thermoplastic powder to the footwearcomponent 201 indiscriminately; e.g., over the entire upward facingsurface of the footwear component 201. The thermoplastic powder can haveany or all of the properties discussed above.

In one or more aspects, as can be seen in FIG. 2, the powder applicator204 can shift along a linear path while applying the thermoplasticpowder to the footwear component 201. In such aspects, the powderapplicator 204 can include a leveler 205 on one edge so that after thepowder applicator extends over the footwear component 201 towards theheating chamber 210, the leveler 205 can level the applied thermoplasticpowder on the footwear component 201 as the powder applicator retractsback over the footwear component 201 in a direction away from theheating chamber 210. In such aspects, having a leveler 205 integrated onthe powder applicator 204 can provide increased efficiency and reducedmanufacturing footprint, since the footwear component 201 can bemaintained a single position to have thermoplastic powder applied andleveled.

In various aspects, after the thermoplastic powder has been applied andlevelled on the footwear component 201, the footwear component 201 canshift positions to be exposed to the thermal energy source 206. In oneaspect, the thermal energy source 206 can include any or all of theproperties of the thermal energy source 108 discussed above withreference to FIG. 1A. For example, in one or more aspects, the thermalenergy source 206 can include a laser energy source.

As discussed above, the vision system 202 can communicate information tothe thermal energy source 206 associated with the orientation, size, andtype of footwear component 201, and/or associated with a pattern forbonding or fusing of the thermoplastic powder on the footwear component201. In aspects, the thermal energy source 206 can supply thermal energyto the thermoplastic powder and/or the footwear component 201 in thepattern desired for the particular footwear component 201. As discussedabove, in aspects, the thermal energy applied can be sufficient to atleast partially bond the thermoplastic powder to the footwear component201 and/or partially bond of fuse together individual particles of thethermoplastic powder.

In aspects, after being exposed to the thermal energy source 206, thefootwear component 201 can be transferred to the un-bonded powderremoval station 208. In certain aspects, the un-bonded powder removalstation 208 can include an air nozzle to expose the footwear component201 to positive (e.g., compressed) or negative (e.g., vacuum) pressureto remove or recover the un-bonded thermoplastic powder. In one aspect,the un-bonded powder removal station 208 supplies positive or negativepressure in an amount sufficient for the removal of the un-bondedthermoplastic powder while not substantially altering the partialbonding between the partially bonded thermoplastic powder and thefootwear component 201. As such, it is contemplated that the partialbonding is sufficient enough to maintain the thermoplastic powder atintended locations during the recovery process at the powder removalstation 208. In certain aspects, as discussed above, the recoveredun-bonded thermoplastic powder can be recycled for re-use in the systemsdisclosed herein or for other purposes. In one aspect, when theun-bonded powder removal station 208 provides positive pressure air forremoval of the un-bonded thermoplastic powder, such air can be heated tothe elevated temperatures discussed above.

In aspects, once the un-bonded thermoplastic powder has been removedfrom the footwear component 201, the footwear component 201 can beexposed to the heating chamber 210. In such aspects, the heating chamber210 can expose the footwear component 201 and/or the partially bondedthermoplastic powder to an elevated temperature. For example, in certainaspects, the footwear component 201 and/or the partially bondedthermoplastic powder can be exposed to a temperature of at least about21° C., at least about 23° C., or at least about 25° C. In aspects, theelevated temperature can be above the glass transition temperature ofthe thermoplastic powder and/or below the melting temperature of thethermoplastic powder. In aspects, the heating chamber 210 can includeany heating source such, as an infrared heating source, a radiantheating source, or other conventional heating sources.

After being exposed to the elevated temperature, the footwear component201 can be compressed to more fully bond the thermoplastic powder to thefootwear component 201. For example, in such aspects, the footwearcomponent can be exposed to a compressive force from the press 212. Inthe aspect depicted in FIG. 2, the press 212 can apply a compressiveforce via a roller. In alternative aspects, the press 212 can apply acompressive force via a planar press.

In various aspects, as discussed above, the compressive force applied bythe press 212 can more permanently attach of fix the thermoplasticpowder to the footwear component 201, which can also result in anincreased density of the thermoplastic powder or material forming thereinforcing component on the footwear component 201.

In various aspects, once the footwear component 201 has been compressed,it can be transferred off the conveyance system 203 onto anotherconveyance system 214 for further processing.

As discussed above, the thermoplastic powder bonded and fixed to thefootwear component can function as a reinforcement for the footwearcomponent. For example, the reinforced component can: function as a ripstop material; function as a structural reinforcement, limit the stretchof a material the thermoplastic powder is bonded to, or function as adimensional offset for a surface of the footwear component. It should beunderstood that other functions of thermoplastic powder reinforcedfootwear components are contemplated by the present invention and thatthe aforementioned list is non-limiting.

In certain aspects, the thermoplastic powder can be bonded to abackside, i.e., an interior-facing side, of the footwear component. Asused herein, “backside” and “interior-facing side” both refer to theside of the footwear component that would face a wearer's foot when inuse, whereas an “exterior-facing side” is located opposite of theinterior-facing side.

In aspects, the thermoplastic powder can be bonded and fixed to thefootwear component in any particular location depending upon the desiredreinforcement needs. In one aspect, the footwear component can be anupper for an article of footwear, such as the article of footwear 300depicted in FIG. 3. In certain aspects, the upper 314 can be reinforced,utilizing the systems and processes described herein, in an ankle collarportion 310, a forefoot opening portion 312, a heel counter portion 304,a toe box portion 302, a medial midfoot portion 308, a lateral midfootportion 306, or a combination thereof. For example, a thermal energysource, e.g., a laser energy source, can apply thermal energy to anycombination of the aforementioned portions of the upper 314 in order tobond and fix a thermoplastic powder thereto. In various aspects, asdiscussed above, a thermoplastic powder can be used to reinforce one ormore of these portions of the upper 314 on the interior-facing side 301.While FIG. 3 depicts a completed article of footwear 300, in certainaspects, the upper 314 may be reinforced while in a flattened stateprior to being incorporated into the completed article of footwear.

As discussed above, the thermoplastic powder fixed to the footwearcomponent can provide a reinforcement functionality, such as structuralintegrity to the upper component as additional processing is occurringto form the completed article of footwear. For example, in certainaspects, as discussed above, prior to being formed into the completedarticle of footwear, the upper may be exposed to a cut in the reinforcedarea, where the bonded thermoplastic powder can provide a rip stopfunctionality to allow a clean cut without further tearing or fraying ofthe upper material.

In aspects, the reinforcement systems and methods described herein cantransfer the footwear component, e.g., an upper, to a cutting toolsubsequent to compressing the thermoplastic powder into the upper toform the reinforced upper. In such aspects, the cutting tool can be anycommon cutting tool used in forming articles of footwear as long as sucha cutting tool is effective to form a cut that extends through thefootwear component and the thermoplastic powder. A non-limiting list ofsuch cutting tools includes a punch, for forming an aperture such as aneyelet, a die cut, a laser, a water jet, a media jet (e.g., sand ormetal media), or a combination thereof.

Once the upper is cut, if necessary, or subjected to additionalprocessing, the upper can be formed into the complete article offootwear. For example, as depicted in FIG. 3, a sole 316 can be combinedwith the upper 314 to form the completed article of footwear 300. Itshould be understood that, as discussed above, the reinforcementprovided by the bonded thermoplastic powder can provide otherreinforcing functionalities in addition to cut or fray protection, suchas wear resistance, structural support, and stretch resistance.

FIG. 4 depicts an exemplary method 400 of reinforcing a footwearcomponent. The method 400 can include the step 402 of applying athermoplastic powder to a footwear component. The thermoplastic powdercan be applied the footwear component as described above with respect tothe systems 100 and 200 of FIGS. 1A and 2, respectively. For example,the thermoplastic powder can be applied using the powder applicator 104or 204 of FIGS. 1A and 2, respectively. The thermoplastic powder caninclude any or all of the properties discussed above.

At step 404, the method 400 includes levelling the thermoplastic powder.In aspects, the thermoplastic powder can be levelled as discussed above,such as by the use of the leveler 106 or 205 described above withreference to FIGS. 1A and 2, respectively.

The method 400 also includes a step 406 of applying thermal energy tothe footwear component. In various aspects, the thermal energy source108 or 206 described above with reference to FIGS. 1A and 2,respectively. For example, in certain aspects, the thermal energy sourcecan include a laser energy source. In aspects, as discussed above, thethermal energy source can selectively apply thermal energy to thethermoplastic powder in a specific position and shape for the desiredreinforcement profile. In various aspects, as discussed above, theapplication of thermal energy to the thermoplastic powder can at leastpartly bond the thermoplastic powder to the footwear component.

At step 408, the partially bonded thermoplastic powder can becompressed. In certain aspects, this compression can cause the partlybonded thermoplastic powder to become more fully bonded or fixed to thefootwear component. In aspects, the thermoplastic powder can becompressed using the press 112 or 212 described above with reference toFIGS. 1A and 2, respectively.

In various aspects, as described above, prior to compressing thethermoplastic powder and subsequent to apply the thermal energy to thethermoplastic powder as in step 406, the un-bonded thermoplastic powdermay be removed, such as by exposing the footwear component to theun-bonded powder removal station 110 or 208 described above withreference to FIGS. 1A and 2, respectively. For example, the footwearcomponent may be exposed to a positive or negative pressure environmentsufficient to remove the un-bonded thermoplastic powder from thefootwear article. In various aspects, this recovered un-bondedthermoplastic powder can be re-used.

Further, as discussed above, in certain aspects, subsequent to applyingthermal energy to the thermoplastic powder (or subsequent to removingthe un-bonded thermoplastic powder) the footwear component may beexposed to another thermal energy source for heating or re-heating thethermoplastic powder prior to compression in step 406. In such aspects,the footwear component can be exposed to thermal energy as discussedabove with reference to the heating chamber 210 of FIG. 2. In the sameor alternative aspects, a heated air stream may be utilized for removingthe un-bonded thermoplastic powder, which can also function to heatingor re-heating the partially bonded thermoplastic powder prior to thecompression of the step 408.

The invention claimed is:
 1. A method of reinforcing a footwearcomponent, the method comprising: applying a thermoplastic powder to thefootwear component; leveling at least a portion of the thermoplasticpowder; selectively applying thermal energy to the footwear component toat least partially bond the thermoplastic powder with the footwearcomponent; and compressing the thermoplastic powder and the footwearcomponent to increase a density of the thermoplastic powder.
 2. Themethod of claim 1, wherein the thermoplastic powder is applied to abackside of the footwear component.
 3. The method of claim 1 furthercomprising determining one or more of a type, a size, a shape, anorientation, and a position of the footwear component and selectivelyapplying the thermal energy based on the one or more determinations ofthe footwear component.
 4. The method of claim 3 further comprisingdetermining the orientation of the footwear component and adjusting anorientation of the selective applying of the thermal energy based on thedetermined orientation of the footwear component.
 5. The method of claim3, wherein the selectively applying of thermal energy originates from alaser energy source.
 6. The method of claim 1 further comprisingremoving at least a portion of the thermoplastic powder from thefootwear component subsequent to applying the thermal energy.
 7. Themethod of claim 6 wherein the removing at least a portion of thethermoplastic powder is comprised of directing an air stream at thethermoplastic powder to be removed.
 8. The method of claim 7, whereinthe air stream is warmer than 21 degrees Celsius.
 9. The method of claim1, wherein compressing the thermoplastic powder occurs subsequent toapplying thermal energy.
 10. The method of claim 6, further comprisingexposing the footwear component to a thermal energy source subsequent tothe removing at least a portion of the thermoplastic powder from thefootwear component and prior to the compressing the thermoplastic powderand the footwear component.
 11. The method of claim 9, whereincompressing the thermoplastic powder is comprised of: a planar pressapplying a compressive force to the thermoplastic powder and thefootwear component; or a roller press applying a compressive force tothe thermoplastic powder and the footwear component.
 12. The method ofclaim 1 further comprising conveying the footwear component in asubstantially horizontal plane while leveling at least a portion of thethermoplastic powder; and conveying the footwear component in asubstantially horizontal plane while applying thermal energy to thefootwear component.
 13. The method of claim 1 further comprising formingan aperture through the footwear component and thermoplastic powdersubsequent to compressing the thermoplastic powder and the footwearcomponent.
 14. The method of claim 1, wherein the thermal energy isapplied to the footwear component at at least one selected from thefollowing: (1) an ankle collar portion; (2) a forefoot opening portion;(3) a heel counter portion; (4) a toe box portion; (5) a medial midfootportion; or (6) a lateral midfoot portion.